MSA 3600 User manual

Model 3600
Infrared Gas Monitor
instruction manual
WARNING
THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILL
HAVE THE RESPONSIBILITY FOR INSTALLING, USING OR SERVICING THIS PRODUCT. Like
anypieceofcomplex equipment,this product will performasdesignedonlyifinstalled,used
and serviced in accordance with the manufacturer’s instructions. OTHERWISE, IT COULD
FAIL TO PERFORM AS DESIGNED AND PERSONS WHO RELY ON THIS PRODUCT FOR
THEIR SAFETY COULD SUSTAIN SEVERE PERSONAL INJURY OR DEATH.
The warranties made by Mine Safety Appliances Company with respect to these products
are voided if the products are not installed, used and serviced in accordance with the
instructions in this manual. Please protect yourself and others by following them. We
encourage our customers to write or call regarding this equipment prior to use or for any
additional information relative to use or repairs.
INSTRUMENT DIVISION 1-800-MSA-INST or FAX [phone]
IN CANADA 1-800-267-0672 or FAX [phone]
MSA INTERNATIONAL [phone] or FAX [phone]
© Mine Safety Appliances Company 1993 - All Rights Reserved
Made in Switzerland for
MINE SAFETY APPLIANCES COMPANY
PITTSBURGH, PENNSYLVANIA 15230
(L) REV 2 800031

Warnings and Cautions
1. Each instrument described in this
manual should be installed, operated,
and maintained in strict accordance
with its labels, cautions, warnings,
instructions, and within the
limitations stated.
2. These monitors must not be installed in
areas or locations where explosive
concentrations of combustible gases or
vapors might occur in the atmosphere:
Class 1, Group A, B, C, and D areas
as defined by the NEC. Because the
monitors are not explosion-proof, they
must be located in non-hazardous
areas.
3. The Model 3600 Infrared Gas Monitor is
designed to detect carbon dioxide or
methane vapors in the air. It cannot
measure the concentration of these
gases or vapors in a steam type
atmosphere. Neither will it indicate the
presence of explosive or combustible
mists or sprays, lubrication oils, nor
explosive dusts such as grain or coal
dust.
4. As with all gas detection instruments of
this type, high levels of or long
exposure to certain compounds in the
tested atmosphere contaminate the
sensor. In atmospheres where the
monitor may be exposed to such
materials, calibration should be
performed frequently to ensure that
system operation is dependable and its
indications accurate.
5. The Model 3600 Infrared Gas Monitor
must not be painted. Also, painting
should not be done near the sample
line inlet. If painting is being done in
an area where the sample line inlet is
located, care must be exercised to
make sure that paint is not deposited
on the sample inlet fitting of the
monitor or sample line. Such paint
deposits would interfere with the
sampling process, whereby a sample of
the atmosphere being monitored is
drawn into the Model 3600 Infrared
Gas Monitor.
6. The only absolute method to assure the
proper overall operation of a gas
detection instrument is to check it
with a known concentration of the
gas for which it has been calibrated.
Consequently, a calibration check
should be included as part of the
routine inspection of the system.
7. The sensor is a sealed unit. No attempt
should be made to modify or adjust
the sensing element.
8. Perform periodic leak checks on the
sample line and all flow system
components and fittings of the Model
3600 Infrared Gas Monitor.
9. Use only genuine MSA replacement
parts when performing any
maintenance procedures provided in
this manual. Failure to do so may
seriously impair instrument
performance. Repair or alteration of
the Model 3600 Infrared Gas Monitor,
beyond the scope of these
maintenance instructions or by
anyone other than authorized MSA
service personnel, could cause the
product to fail to perform as
designed, and persons who rely on
this product for their safety could
sustain severe personal injury or
death.
10. Properly vent the exhaust of the Model
3600 Infrared Gas Monitor to a safe
area. Improper venting of the
exhaust can cause personal injury or
death.
11. Ensure that the gas sample to the
Model 3600 Infrared Gas Monitor is
clean and dry as possible. Install
filters into the sample inlet fittings as
necessary to obtain a clean and dry
gas sample.
12. Ensure that the gas sample and Model
3600 Infrared Gas Monitor are at the
same temperature; otherwise,
condensation will form and possibly
clog or fill the sample line.
Model 3600 Infrared Gas Monitor Warnings and Cautions

Model 3600 Infrared Gas Monitor

Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-1. Identification Label Location . . . . . . . . . . . . . . . . . . . . . . 1-1
General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Operating Specifications for all Models. . . . . . . . . . . . . . . . . . . . 1-2
Section 2
Installation and Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unpacking the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unpacking the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mounting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Flow Sample Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Sample System Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Sample System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-1. Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Sample System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-2. Bottom View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Opening the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-3. Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Analog Signal Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Relay Connections Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-4. Meter Printed Circuit Board Shown in Configuration 1 2-5
Flow Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Model 3600 Infrared Gas Monitor Table of Contents
TOC - 1

Section 3
Start-up and Initial Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Figure 3-1. Readout and Controls . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Power-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Alarm Setting Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Alarm Level Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Alarm Level Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General Calibration (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Section 4
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Calibration Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Calibration Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Accessing the CalibrationControls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Applying Calibration Gases to the Instrument . . . . . . . . . . . . . . . . . 4-1
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Section 5
Service and Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Troubleshooting Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Service and Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Table 5-1. Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Table 5-2. Replacement Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-3. Calibration Accessories Parts List. . . . . . . . . . . . . . . . . . . . . . 5-2
Table of Contents Model 3600 Infrared Gas Monitor
TOC - 2

Section 1
General Information
The Model 3600 Infrared Gas Monitor
provides a continuous indication of carbon
dioxide or methane concentration. It is
capable of monitoring carbon dioxide from
0.2% to 50% or methane up to 10%
depending on the model. Each instrument is
factory-calibrated to a certain full-scale value
of these two gases.
All Model 3600 Infrared Gas Monitors use
an infrared photo-acoustic sensor. This
sensor gives an indication of the carbon
dioxide or methane levels without requiring
that oxygen be present. Also, this sensor is
not poisoned or degraded in the presence of
silicon or sulfur compounds.
Each Model 3600 Infrared Gas Monitor draws
a gas sample to its internal sensor through a
sample line. The sample line is routed to the
area where gas monitoring is desired. The
Model 3600 Infrared Gas Monitor contains all
the flow components necessary, excluding the
sample line, to properly sample an area.
This manual describes all of the various
Model 3600 Infrared Gas Monitors; your
monitor may not be equipped with all of the
options available. To help you determine
what options are on your unit, there is an
identification label on the side of the
instrument (see FIGURE 1-1). This label
contains the Model number, the gas that
the unit will respond to, and its range. It
also contains information concerning the
proper power voltages and frequency along
with the output signal.
Terminology
The following is an outline of terminology
used in this manual:
ZERO
A zero (0) indication on the meter display
usually indicates ambient air present or no
hazardous gases present.
ZEROING
The process of placing a zero indication on
the meter display.
SPAN
A full-scale or up-scale reading on the
meter display.
SPANNING
The process of placing a full-scale or
up-scale meter reading on the display.
SPAN GAS VALUE
The gas "concentration" that will give the
instrument a full-scale or up-scale value.
This value is printed on the gas cylinder
containing the gas.
FLOW RATE
The speed of the gas in the sample line.
EXHAUST GAS
The gas after it has passed the sensor.
PUMP
An electric motor which drives a device
that moves the gas sample to the Model
3600 Infrared Gas Monitor.
Figure 1-1. Identification Label Location
Model 3600 Infrared Gas Monitor Section 1, General Information
1-1

LO ALARM RELAY
A relay that activates when the gas level
exceeds a low level threshold.
HI ALARM RELAY
A relay that activates when the gas level
exceeds a high level threshold.
General Description
The Model 3600 Infrared Gas Monitor:
•Provides a continuous indication of a
gas or vapor concentration.
•Is capable of measuring Carbon Dioxide
from Parts Per Million (PPM) to 50%.
•Employs photo-acoustic infrared
analysis, and can detect combustible
gases or vapors in applications where
contaminants, interferants, or lack of
oxygen preclude the use of other
techniques.
•(Standard model) is housed in a rugged
plastic enclosure.
•Has a front-panel window that allows
the user to view the meter, the power
LED, and the LEDs indicating each
level of alarm.
•Comes standard with two sets of relay
contacts, a choice of three analog
outputs, and can be powered from one
of six available power supplies.
•Is highly selective to enable operation in
areas with varying humidity or in areas
containing other contaminants. It may be
used for applications requiring long-term
stability and low maintenance.
An optional internally-mounted flow switch is
available to help ensure the sample gas is
getting to the unit. This is especially useful
for sampling dirty or wet remote areas which
may clog the sampling line to the instrument.
Applications
The Model 3600 Infrared Gas Monitor is
factory-calibrated for carbon dioxide or
methane. When calibrated for either of
these gases, the Model 3600 Infrared Gas
Monitor can be used in a wide variety of
industrial applications such as:
•Ventilation control.
•Leak detection of combustible gases
into ambient areas.
•Ambient air monitoring for health and
safety purposes.
•Monitoring levels of combustible gases in
wastewater or sewage treatment plants.
•Flue gas and heat treat systems analysis
•Process monitoring in fermentation,
carbonation, and other food industry
processes.
General Operating Specifications for all Models
PERFORMANCE SPECIFICATIONS
STABILITY SHORT-TERM +1%
LONG-TERM INCLUDING LINEARITY ERROR +5% in 18 months
NOISE +.5% Full-Scale Max.
WARM-UP TIME Five minutes
RESPONSE TIME 97% of a step-change in 12 seconds
OPERATING TEMPERATURES 0 to 50 degrees Centigrade (32 to 122 degrees Fahrenheit)
TEMPERATURE EFFECT <4%/10 degrees Kelvin
RELATIVE HUMIDITY 20 to 99%, RH non-condensing
SAMPLE FLOW RATE 0.8 liters per minute, typical
MAXIMUM TUBING LENGTH 300 feet (100 meters)
OPERATING SPECIFICATIONS
POWER REQUIREMENT 10 VA
ALARM RELAYS One relay for each level of alarm, Form C contacts: 120 VAC, 1 amp resistive
Section 1, General Information Model 3600 Infrared Gas Monitor
1-2

General Operating Specifications for all Models
OPERATING SPECIFICATIONS
ANALOG OUTPUT 4 to 20 mA, or 0 to 1 Volt, or 0 to 10 Volts
MAXIMUM OUTPUT SIGNAL LOAD 500 Ohms
SAMPLE TUBING CONNECTIONS 1/4 inches (6 millimeter) OD; 5/32 inches (4 millimeter) ID
OPTIONAL FLOW SWITCH Dry contact 120 VAC, 1 Amp resistive
DIMENSIONS 7.6 inches high, 7.25 inches wide, 5.3 inches deep.193 millimeters high, 184
millimeters wide, 135 millimeters deep
WEIGHT 4.4 pounds (2 Kilogram)
TRANSPORT AND STORAGE CONDITIONS
TEMPERATURE -40 to +70 Degrees Centigrade
HUMIDITY 99% relative humidity
VIBRATION 7 Gs
INFLUENCE ERRORS
TEMPERATURE <0.4% full scale / Degree Kelvin
HUMIDITY +0.05% full scale / % relative humidity
PRESSURE +0.1% full scale mBar
INTERFERENCE ERRORS
N2, O2, AIR, He No photo-acoustic effect
CH4+4.2 ppm CO2reading/ 1% CH4
CO, SO2, NO, O30.50 ppm CO2reading/ 1%
Model 3600 Infrared Gas Monitor Section 1, General Information
1-3

Section 2
Installation and Set-up
Unpacking the Unit
This section provides instructions on
unpacking and inspecting the equipment,
mounting the monitor, and making electrical
connections to the unit.
Unpacking the System
Carefully remove the Model 3600 Infrared
Gas Monitor from its shipping container(s). To
keep from inadvertently discarding usable or
valuable parts, search through the packing
material and the inside all of the containers.
Remove the closure pin (see FIGURE 1-1) by
sliding it out of the Model 3600 Infrared Gas
Monitor, and open the front cover. Remove all
packing material from inside the unit.
WARNING
Do not operate the unit with the packing
material inside the unit; otherwise, the
unit will not operate properly.
Retain all packaging and packing material
in case it is necessary to return the unit.
Initial Inspection
1. With the front cover open, carefully
inspect the components and
assemblies inside the enclosure.
2. If damage or shortage is noted, advise
the carrier promptly. Make the proper
claim with the carrier.
3. Loosen the two Phillips screws on the
bottom electrical cover to release the
plastic bag (FIGURE 2-3). This bag
contains some mounting hardware
and a sample line filter.
4. Re-install the cover, and tighten the
Phillips screws.
5. Close the front cover, and re-install
the closure pin.
Mounting the Unit
Guidelines
Five rules for proper mounting are:
1. Do not mount the unit to structures
subject to vibration and shock.
2. Do not locate the unit near an excessive
heat source.
3. For proper cooling, allow at least three
inches of clearance around all surfaces,
except for the mounting surface.
4. Do not mount the unit where it will be
exposed to direct sunlight.
5. Mount the unit where the front panel
will not be obscured from view.
Mounting
The monitor should be mounted in a location
that is as free from shock and vibration as
possible. The system should be protected
from extreme vibration. Do not mount in
direct sunlight as this may cause overheating
of the unit. Mount the unit so that its front
panel is not blocked or obscured from view.
Allow four inches of space around the unit
to allow the front door of the instrument
to open fully.
WARNING
These units must not be located in an
area that may contain a flammable
mixture of gas and air; otherwise, an
explosion may occur.
Model 3600 Infrared Gas Monitor Section 2, Installation and Set-Up
2-1

CAUTION
Make sure that the door of the model
3600 Infrared Gas Monitor unit is not
blocked or obscured so as not to block
or obscure the display.
1. Remove the enclosure pin, and open unit.
2. Remove the electrical wiring cover by
loosening the two Phillips screws.
3. Securely mount the Model 3600
Infrared Gas Monitor to a wall or any
flat mounting surface via the four holes
in the back of the instrument, using
the standoffs and screws supplied in
the plastic bag (see FIGURE 2-1).
Ensure that the sample inlet and outlet
on the bottom of the instrument are
pointed downward.
4. Re-install the electrical cover, and
tighten the Phillips screws.
5. Close the front cover, and re-install
the closure pin.
Flow Sample Installation
Sample System Connections
Sample and exhaust fittings are provided
on the Model 3600 Infrared Gas Monitor.
These are barbed fittings designed for use
with 1/4" OD tubing. Route the sample
tubing to the area to be monitored. For
proper operation, the following sample
system requirements must be met.
Sample System Requirements
The following conditions must exist for proper
Model 3600 Infrared Gas Monitor operation:
1. A flowing sample must be maintained
through the unit between 0.5 to 1.0
LPM; if so equipped, the internally
mounted sampling pump is used for
this purpose.
2. Place the end of the sampling line in an
area that will provide the Monitor with
a representative sample; ventilation
Smoke Tubes (P/N 458480) are useful
in determining air flow patterns in
ambient sampling areas.
3. If the sample stream contains toxic or
combustible gases, make sure the
unit is properly exhausted.
4. Ensure the sampling area is free of
particulate matter and condensing
liquids.
NOTE: On an instrument not
equipped with an internal
pump, the sample must be
Figure 2-1. Mounting Dimensions
Section 2, Installation and Set-Up Model 3600 Infrared Gas Monitor
2-2

adequately filtered before
entering the instrument.
5. Ensure that the end of the sampling
line is unobstructed, allowing the
sample to flow freely to and through
the sampling line. If no sampling line
is used, ensure that the sample fitting
on the bottom of the enclosure is
unobstructed.
6. Keep sample lines as short as possible
to reduce gas sample transport time.
7. Only use materials in the sample tubing
and other sample system components
that are compatible with the gas stream.
8. Before use, check to make sure that the
sampling line is free of any cracks,
kinks, or other defects. Also make sure
the sampling line is not obstructing the
Model 3600 Infrared Gas Monitor or
any other machinery, walkways, etc.
9. DO NOT back-pressure the exhaust line
on the Model 3600 Infrared Gas
Monitor, or connect it to a vacuum
source. If no exhaust line is necessary,
make sure the exhaust fitting on the
bottom of the case is unobstructed.
10. A flowmeter can be installed along the
sampling line to monitor the flow to
the unit. If a flowmeter is used in
conjunction with the internally
mounted pump, adjust the flow at the
flowmeter. DO NOT install a flowmeter
in the exhaust line.
Sample System Installation
1. Remove all caps and fittings on the inlet
and outlet of the Model 3600 Infrared
Gas Monitor (see FIGURE 2-2).
CAUTION
Failure to remove the caps from the inlet
or outlet fittings of the Model 3600
Infrared Infrared Gas Monitor will not
let the instrument sample the gas. This
may cause an undetected dangerous gas
buildup to occur which may result in
an explosion or death.
2. Remove the filter from the plastic bag,
and insert the clear end over the inlet
fitting of the Model 3600 Infrared
Infrared Gas Monitor. The black end
of the filter should be pointing down.
3. Route the 1/4" tubing to the area to
be monitored.
4. Install the tubing to the inlet fitting of
the filter on the Model 3600 Infrared
Gas Monitor.
5. If necessary, install and route the
exhaust tubing on the outlet of the
Model 3600 Infrared Gas Monitor. Route
this tubing to a well ventilated area. The
exhaust tubing must be at least one size
larger than the sample line.
Figure 2-2. Bottom View
Model 3600 Infrared Gas Monitor Section 2, Installation and Set-Up
2-3

Wiring Connections
Opening the Unit
All wiring to the Model 3600 Infrared Gas
Monitor is made via the bottom entries.
The wiring access cover of the monitor
may be opened to provide complete access
to all wiring connections.
CAUTION
Do not open the wiring access cover
unless the monitor is protected from
splashing, spraying, or dripping water;
otherwise, damage to the internal
components may result.
Remove the wiring access cover by removing
the two Phillips screws. This will expose the
chassis assembly and terminal strip for
customer connections (FIGURE 2-3).
Wiring
The Model 3600 Infrared Gas Monitor is
factory-wired with one of six power
supplies:
•120 volts 60 Hz AC
•240 volts 60 Hz AC
•24 volt 50 Hz AC
•110 volts 50 Hz AC
•220 volts 50 Hz AC
•240 volt 50 Hz AC
Determine the power supply for your
Model 3600 Infrared Gas Monitor (see
FIGURE 1-1). All wiring is done via the
openings in the bottom of the enclosure.
CAUTION
If unsure of the power voltage available,
contact your plant engineer or safety
officer. Damage may occur to the
instrument if the wrong power voltage is
applied to the instrument.
Figure 2-3. Wiring Connections
Section 2, Installation and Set-Up Model 3600 Infrared Gas Monitor
2-4

All power wiring is connected to the left side
of the eight-position terminal block. Connect
the "HOT" AC wire to terminal #L on the
connector and connect the "Neutral" or ACN
lead to terminal #2. Connect a ground wire
on terminal #3 (see FIGURE 2-3). Power
wiring and the ground wire should be routed
through electrical entry holes in the case as
shown in FIGURE 2-2. Note that power
wiring should be separated from relay wiring.
Analog Signal Output Wiring
The Model 3600 Infrared Gas Monitor is
factory-configured with one of three analog
outputs ranges. Determine the analog
output for your Model 3600 Infrared Gas
Monitor (see FIGURE 1-1):
•4-20 mA, current sourcing type
•0-1 VDC
•0-10 VDC
The output connections are located on the
eight-position connection terminal strip on
the bottom of the enclosure. Terminals #7
(+) and #8 (-) are available for the signal
output and signal return (see FIGURE 2-3).
Relay Connections Wiring
Two sets of relay contacts are available on
the Model 3600 Infrared Gas Monitor. There
is a high and a low alarm set-point with
corresponding relays. The relay contacts are
available through the six-position terminal
strip located on the bottom right of the
enclosure. FIGURE 2-3 shows the relay
configuration for wiring.
Each relay contact is rated for 120 VAC, 1
amp resistive loads. When the relays are
activated, the front panel LED will light.
Each relay has contacts for:
•Normally Open (N/O)
•Common (C), and
•Normally Closed (N/C)
The function and wiring of each relay
connector terminal is indicated on
FIGURE 2-3.
Relay Operation
The HI relay is activated when the signal
from the sensor exceeds the alarm
set-point. (See the Alarm Set-point
Adjustment section later in the manual.)
The LO relay can be configured in one of
two ways. There is a jumper on the printed
circuit board behind the front panel which
will permit LO relay to operate in one of the
following configurations:
1. The LO Relay is energized when the
gas is below the low alarm set point.
2. The LO Relay is energized when the
signal is above the low alarm set point.
Configuration #1: useful in greenhouses or
in any application where a constant level of
gas is being maintained. The LO alarm
set-point indicates that additional gas is
necessary to maintain the desired level.
Configuration #2 (of the LO relay): used
to alarm when the gas is increasing. This
configuration is used when safety of
personnel or equipment is involved.
Selecting LO Alarm Relay Configuration
The selection jumper for the LO relay is
located on the meter printed circuit-board
located behind the front panel of the
instrument.
1. Open the instrument for access to this
jumper by removing the closure pin
(see FIGURE 1-1) and opening the
enclosure.
Figure 2-4. Meter Printed Circuit Board
Shown in Configuration 1
Model 3600 Infrared Gas Monitor Section 2, Installation and Set-Up
2-5

2. Locate the meter printed circuit board
and move the jumper to the desired
position (see FIGURE 2-4).
•Position #1 enables configuration 1
•Position #2 enables configuration 2
NOTE: This configuration option is
available only on the LO relay.
The High relay always energizes
when the gas is higher than the
HI alarm set-point.
3. Close the front cover, and re-install
the closure pin.
Flow Switch Wiring
The optional flow switch is open (no electrical
contact) when there is no flow present. The
flow switch closes when flow is detected.
There is a two-position connector for
electrical connection to the flow switch.
These connections can be made to operate
a light, horn or other warning devices to
alert the operator.
Another possible connection is to put the
output signal of the instrument through
the switch. When flow is not detected, the
output signal is interrupted. Loss of signal
may be detected by a controller connected
to the output signal.
Re-install the electrical cover, and tighten
the Phillips screws. Close the front cover,
and re-install the closure pin.
Section 2, Installation and Set-Up Model 3600 Infrared Gas Monitor
2-6

Section 3
Start-up and Initial Adjustments
Operation
This section describes procedures for
operating all system controls and indicators:
•Start-up procedure
•Making alarm-level adjustments
•Placing the system into operation
•Initial instrument calibration
•Controls and indicators
FIGURE 3-1 shows the location of the
instrument controls and indicators. The
following information lists these controls
and describes their function.
Control Description
Meter Zero Control
Sets the meter zero.
LO Level Control
Sets the instrument’s low-level alarm set-point.
MEAS Switch
Shows the current value of the LO or HI
alarm point value on the meter when the
switch is thrown in the respective position.
HI Level Control
Sets the instrument’s high-level alarm
set-point.
Power LED
Lights when power is applied to the unit.
ZERO Control
Adjusts the zero of the instrument.
Figure 3-1. Readout and Controls
Model 3600 Infrared Gas Monitor Section 3, Start-Up and Initial Adjustments
3-1

SPAN Control
Adjusts the span of the instrument.
PUMP Switch
Turns the pump ON or OFF.
Power-up
1. Before applying power to the unit, be
certain that the front-panel meter
needle points to ZERO; if it does not:
a. Open the clear front cover of the
instrument by loosening the two
thumb screws securing the cover.
b. Locate the METER ZERO Adjustment
directly below the meter face.
c. Turn the METER ZERO Adjustment
with a small slotted screwdriver
until the meter needle reads ZERO.
d. Close the front cover, and reinstall
the two Phillips screws; tighten the
screws to secure the front cover.
2. Turn the instrument power on at the
circuit-breaker supplying power to
the instrument. (The instrument does
not have a power switch.)
3. When the power is turned ON, the front
panel power LED should light. If the
instrument does not turn ON, verify the
wiring is connected properly and power
is being applied to the terminal strip.
4. Ensure the pump in the instrument, if
so equipped, is running. If the pump
is not running, turn the pump switch
to the ON position (see FIGURE 3-1).
The LO alarm LED may light when the
instrument is first turned ON, depending
on the configuration of the LO alarm. (See
Selecting LO Alarm Relay Configuration in
this manual.) Any clicking or snapping
noises are part of normal sensor operation.
After stabilization, set the alarm levels and
calibrate the instrument.
Alarm Setting Feature
There are two alarm levels in the Model
3600 Gas Monitor and a relay for each
level. Each alarm level is set independently
of each other and of the level of the gas
entering the instrument.
Alarm Level Setting
Alarm Level Adjustment Procedure
(Refer to FIGURE 3-1.)
1. Open the clear front cover of the
instrument by loosening the two
thumb screws securing the cover.
2. Press and hold the MEAS switch to
either the LO or HI position. When the
MEAS switch is in the LO position, the
meter displays the LO alarm value; in
the HI position, the meter displays the
HI alarm value.
3. While holding the MEAS switch in the
LO position, adjust the LO control to
the desired LO alarm activation value.
4. While holding the MEAS switch in the
HI position, adjust the HI control to
the desired HI alarm activation value.
5. When the MEAS switch is released,
the Model 3600 gas monitor stores
the new alarm values and resumes
normal operation.
General Calibration (All Models)
Perform the calibration procedure regularly;
maintain a log of calibration adjustments.
Increase the frequency of calibration when
any calibration shows as much as 10%
difference from the test gas concentration.
More frequent calibrations may be required
when the Model 3600 unit is new, or if the
sensor is dirty. Also, perform the calibration
procedure when installing or changing the
power source, the sample line, or the control
instrumentation. If this calibration procedure
cannot be performed at any step, consult the
Troubleshooting section; localize the problem
and replace the inoperative component.
Frequency of calibration depends on the
operating time and chemical exposures of the
instrument. Calibrate newly installed
instruments more often, until the calibration
records prove instrument stability. Calibration
frequency can then be reduced to a schedule
set by the safety officer or facility manager.
Section 3, Start-Up and Initial Adjustments Model 3600 Infrared Gas Monitor
3-2

Section 4
Calibration
Calibration Guidelines
Once the Model 3600 Gas Monitor is
operating, perform periodic calibration
checks to ensure proper instrument
operation and to monitor the long-term
changes (drift) in both the ZERO and
SPAN readings. If there is an unacceptable
change in either of these readings, make
adjustments to obtain proper readings.
If routine calibration does not restore the
proper readings, perform the Initial
Calibration Procedure. If the Initial Calibration
Procedure fails to restore the proper
instrument readings, consult the
Troubleshooting Section of this manual for
guidelines to correct the instrument.
Maintain a log of the calibration readings
obtained and any adjustments that were
made. Analysis of this record will enable
varying the time between checks. Check a
new installation of the Model 3600 Gas
Monitor a minimum of once a week.
Calibration Equipment
Equipment needed:
•Calibration kit (P/N 492769).
•ZERO Gas or ZERO air (P/N 801050).
•SPAN Gas - A known gas concentration
that is 45% to 55% of the full-scale
calibration of the unit, or as indicated
on the identification label on the side of
the instrument (see FIGURE 1-1).
Apply both ZERO gas and SPAN carefully
to the unit in order to avoid pressurizing
the internally mounted sensor. See TABLE
5-3, Calibration Accessories Parts List, for
the appropriate calibration gases.
Calibration Procedures
The calibration procedure involves checking
and adjusting the amplifier SPAN and ZERO
potentiometers on the instrument, if necessary.
During the calibration procedure, the alarm
relays may activate. Disconnect or disable
any equipment or alarms connected to the
Model 3600 Gas Monitor’s alarm relays
during the calibration procedure.
Accessing the
CalibrationControls
The front panel door of the Model 3600 Gas
Monitor may be opened to provide complete
access to SPAN and ZERO potentiometers.
CAUTION
Do not open the front panel door unless
the instrument is protected from
splashing, spraying, or dripping water;
otherwise, damage to the internal
components may result.
Applying Calibration Gases to the
Instrument
1. Remove sampling tubing from the
sample inlet fitting on the bottom of
the enclosure.
CAUTION
During calibration, the Monitor is not
samplingandmonitoringtheintendedarea.
Exercise caution in the area as appropriate.
2. Verify the pump switch is in the ON
position and that the pump is running.
3. Attach the flow control from the
Calibration kit to the ZERO calibration
gas tank; attach the tubing from the
Model 3600 Infrared Gas Monitor Section 4, Calibration
4-1

Calibration kit to the instrument and
flow controller.
4. The FLOW FAILURE switch, if
equipped, may momentarily activate
when the tubing is connected. Then,
open the flow controller valve.
5. Turn the pump switch to the off
position. The FLOW FAILURE switch,
if equipped, activates when the pump
is switched OFF.
6. After 3 minutes, adjust the ZERO
control to obtain a zero reading on
the meter (see FIGURE 3-1).
7. Turn OFF the flow controller and move
it to the SPAN gas cylinder.
8. Turn ON the flow controller for at least
two minutes.
9. Adjust the SPAN control to obtain a span
reading on the meter (see FIGURE 3-1).
10. Remove SPAN gas cylinder from
instrument.
11. Turn the pump switch to the on
position. The FLOW FAILURE switch
will reset itself when the pump is
switched ON.
WARNING
Do not leave the pump switch OFF;
otherwise, the instrument cannot draw a
sample to the sensor.
12. Reconnect all sampling lines to the
instrument.
WARNING
Do not leave off any sampling line to the
instrument; otherwise, the instrument
cannot sample its intended area.
13. Close and secure the instrument lid.
14. Re-connect or enable all equipment
and alarm devices connected to the
Model 3600 Gas Monitor alarm relays.
CAUTION
Do not leave any alarm devices or
equipment disabled or disconnected during
normal instrument operation; otherwise,
theinstrumentwillnotfunctionasintended
when it detects an alarm situation.
Section 4, Calibration Model 3600 Infrared Gas Monitor
4-2

Section 5
Service and Replacement Parts
Troubleshooting Guidelines
The Model 3600 Gas Monitor is designed to
provide long and trouble-free monitoring.
Occasionally, however, repairs may be
required. It may be possible for the user to
diagnose and correct the problem by
following the Troubleshooting Guidelines in
TABLE 5-1, and referring to the Replacement
Parts Lists in TABLES 5-2 and 5-3.
Service and Assistance
To order replacement parts or obtain
assistance regarding any problem with the
Model 3600 Gas Monitor, please provide
the serial number and model number. This
information can be found on a label
located on the outside of the instrument.
Parts or assistance can be obtained by
contacting your closest MSA representative or:
Mine Safety Appliances Company
Instrument Division, Sales Department
P.O. Box 427, Pittsburgh, PA 15230
(1-800-MSA-INST)
Table 5-1. Troubleshooting Guidelines
SYMPTOM CAUSE SOLUTION
POWER LED does not
turn ON
1) Customer input power interrupted 1) Check and correct input power*
2) Bad connection between power cable
and connector 2) Check wiring
3) Inoperative LED 3) Replace LED
4) Improper voltage 4) Make proper voltage wiring
5) Inoperative power supply 5) Replace power supply
Known alarm
conditions exist and
readout is correct, but
LED descriptors do not
turn ON
1) Alarm set-points are set too high 1) Re-set Alarm set-points
2) Inoperative LED 2) Replace LED
3) Pump not ON 3) Turn pump ON
Readout does not
indicate condition 1) Non-calibrated instrument 1) Calibrate or turn pump ON
2) Inoperative or dirty sensor 2) Replace printed circuit-board
Alarm descriptors will
not turn OFF, and
readout indicates
non-hazard condition
1) Improperly set Alarm set-points 1) Re-adjust set-points
2) Printed circuit-board inoperative 2) Replace meter-printed circuit-board
Remote devices
inoperative
1) Remote devices improperly connected 1) Verify remote device wiring connections
2) LO Relay jumper improperly set 2) Verify and re-set LO relay jumpers
3) No output from current loop connections 3) Verify and re-connect current output connections
4) Low output from current loop connections 4) Reduce external load to 250 ohms or less
FLOW FAILURE switch
(optional) is always ON
1) Sample tubing blocked 1) Check flow tubing
2) Dirty filter 2) Replace filter
3) Pump inoperative 3) Turn pump ON or replace pump
4) Exhaust blocked 4) Check exhaust
*CAUTION: Exercise caution as potential shock hazard exists
Model 3600 Infrared Gas Monitor Section 5, Service and Replacement Parts
5-1

Table 5-2. Replacement Parts List
COMPONENT/ASSEMBLY PART NO.
CHASSIS ASSEMBLY MODEL 3600
PC Board Assembly, Main 696602
PC Board Assembly, Meter 696603
Meter 696604
PUMP AND FLOW SWITCH ASSEMBLY
Pump Assembly 696605
Flow Switch Assembly 696606
Filter 696607
Tubing 602294
Table 5-3. Calibration Accessories Parts List
Calibration Kit 492769
5-Liter Tedlar Sample Bag 472992
Shut-Off Assembly Connector 471722
99.9% Nitrogen 481317
1300 ppm CO2in Nitrogen, 2.5% CH4801041
2000 ppm CO2in Nitrogen, 2.5% CH4801042
3300 ppm CO2in Nitrogen, 2.5% CH4801043
6600 ppm CO2in Nitrogen, 2.5% CH4801044
1.3% CO2in Nitrogen, 2.5% CH4801045
3.3% CO2in Nitrogen, 2.5% CH4801046
6.6% CO2in Nitrogen, 2.5% CH4801047
33.3% CO2in Nitrogen 801048
6.6% Methane in Nitrogen 801049
2.5% Methane in Air 491041
Zero Air 801050
Section 5, Service and Replacement Parts Model 3600 Infrared Gas Monitor
5-2